Reinforced faces of club heads and related methods

ABSTRACT

Some embodiments include a reinforced face of a club head. Other embodiments for related reinforced faces of club heads and related methods are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. Non-Provisionalpatent application Ser. No. 13/407,559, filed Feb. 28, 2012, andInternational Patent Application No. PCT/US2012/038681, filed May 18,2012. International Patent Application No. PCT/US2012/038681 is acontinuation of U.S. Non-Provisional patent application Ser. No.13/407,559. U.S. Non-Provisional patent application Ser. No. 13/407,559and PCT/US2012/038681 are incorporated herein by reference in theirentirety.

TECHNICAL FIELD

This disclosure relates generally to sports equipment, and relates moreparticularly to reinforced faces of club heads and related methods.

BACKGROUND

The center of gravity of a golf club can be strategically positionedaccording to the desired performance of the golf club. Because theposition of the center of gravity of the golf club is dependent on thedistribution of mass of the golf club and because it is often desirable,for performance purposes, to move the center of gravity down toward thesole and/or away from the face of the golf club head, the face of thegolf club head may be made thin in order to move mass to the sole and/oraway from the face. Thinning the face permits the center of gravity tobe more strategically positioned, but may have side effects, such as,for example, reducing the strength and/or durability of the face and/orthe golf club as a whole.

Meanwhile, the vibrational frequency of the face and/or golf club isanother factor that may affect the performance of a golf club. Thevibrational frequency of the face and/or golf club can be related to theelasticity of the face, golf club head, and/or golf club.

BRIEF DESCRIPTION OF THE DRAWINGS

To facilitate further description of the embodiments, the followingdrawings are provided in which:

FIG. 1 illustrates a rear view of a front face for a club head when thefront face is apart from the club head, according to an embodiment;

FIG. 2 illustrates an x-ray view of the front face when the front faceis part of the club head, according to the embodiment of FIG. 1;

FIG. 3 illustrates a rear view of another front face for a club headwhen apart form the club head, according to another embodiment;

FIG. 4 illustrates a rear view of another front face for a club headwhen apart form the club head, according to another embodiment;

FIG. 5 illustrates a rear view of another front face for a club headwhen apart form the club head, according to another embodiment;

FIG. 6 illustrates a flow chart for an embodiment of a method ofproviding a front face and/or a club head;

FIG. 7 illustrates an exemplary procedure of providing the front face toinclude a front surface and a back surface opposite the front surface,according to the embodiment of FIG. 6;

FIG. 8 illustrates an exemplary procedure of providing one or morereinforcing structures at the back surface of the front face, accordingto the embodiment of FIG. 6; and

FIG. 9 illustrates an exemplary process of coupling the reinforcingstructure(s) with the front face at the back surface, according to theembodiment of FIG. 8.

For simplicity and clarity of illustration, the drawing figuresillustrate the general manner of construction, and descriptions anddetails of well-known features and techniques may be omitted to avoidunnecessarily obscuring the invention. Additionally, elements in thedrawing figures are not necessarily drawn to scale. For example, thedimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help improve understanding of embodimentsof the present invention. The same reference numerals in differentfigures denote the same elements.

The terms “first,” “second,” “third,” “fourth,” and the like in thedescription and in the claims, if any, are used for distinguishingbetween similar elements and not necessarily for describing a particularsequential or chronological order. It is to be understood that the termsso used are interchangeable under appropriate circumstances such thatthe embodiments described herein are, for example, capable of operationin sequences other than those illustrated or otherwise described herein.Furthermore, the terms “include,” and “have,” and any variationsthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, system, article, device, or apparatus that comprises alist of elements is not necessarily limited to those elements, but mayinclude other elements not expressly listed or inherent to such process,method, system, article, device, or apparatus.

The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,”“under,” and the like in the description and in the claims, if any, areused for descriptive purposes and not necessarily for describingpermanent relative positions. It is to be understood that the terms soused are interchangeable under appropriate circumstances such that theembodiments of the invention described herein are, for example, capableof operation in other orientations than those illustrated or otherwisedescribed herein.

The terms “couple,” “coupled,” “couples,” “coupling,” and the likeshould be broadly understood and refer to connecting two or moreelements mechanically and/or otherwise. Two or more mechanical elementsmay be mechanically coupled together, but not be electrically orotherwise coupled together. Coupling may be for any length of time,e.g., permanent or semi-permanent or only for an instant.

“Electrical coupling” and the like should be broadly understood andinclude coupling involving any electrical signal, whether a powersignal, a data signal, and/or other types or combinations of electricalsignals. “Mechanical coupling” and the like should be broadly understoodand include mechanical coupling of all types.

The absence of the word “removably,” “removable,” and the like near theword “coupled,” and the like does not mean that the coupling, etc. inquestion is or is not removable.

DETAILED DESCRIPTION

Some embodiments include a club head. The club head comprises a frontface, and the front face comprises a front surface and a back surfaceopposite the front surface. Likewise, the front face comprises one ormore reinforcing structures. The reinforcing structure(s) are coupledwith the front face at the back surface. Meanwhile, the reinforcingstructure(s) comprise a solidified welding material. Also, thereinforcing structure(s) are devoid of adjoining structure other thanthe front face.

Various embodiments include a club head. The club head comprises a frontface, one or more reinforcing structures, and a void adjacent to theback surface. Meanwhile, the front face comprises a front surface and aback surface opposite the front surface. The reinforcing structures (a)are coupled with a non-edge portion of the front face at the backsurface, (b) comprise a solidified welding material, and (c) are boundedby only the back surface and the void when the reinforcing structure(s)are coupled with the front face at the back surface. Meanwhile, thefront face comprises a front face material, and the solidified weldingmaterial comprises a filler material. Likewise, the reinforcingstructure(s) form one or more layers at the back surface, and each ofthe layer(s) substantially forms one of a spiral pattern, a crosspattern, or a striped pattern. Further still, the club head comprisesone of a driver-type club head, a fairway wood-type club head, ahybrid-type club head, an iron-type club head, a wedge-type club head,or a putter-type club head.

Further embodiments include a method. The method comprises: providing afront face of a club head, where the front face comprises a frontsurface and a back surface opposite the front surface; and providing oneor more reinforcing structures at the back surface of the front face,wherein (a) the one or more reinforcing structures comprise a solidifiedwelding material, and (b) the one or more reinforcing structures aredevoid of adjoining structure other than the front face.

Meanwhile, some embodiments include a club head. The club head comprisesa front face, and the front face comprises a front surface and a backsurface opposite the front surface. Likewise, the front face comprisesone or more reinforcing structures. The reinforcing structure(s) arecoupled with the front face at the back surface. Meanwhile, thereinforcing structure(s) consist of a solidified welding material. Also,the reinforcing structure(s) are devoid of adjoining structure otherthan the back surface of the front face.

Various embodiments include a club head. The club head comprises a frontface, one or more reinforcing structures, and a void adjacent to theback surface. Meanwhile, the front face comprises a front surface and aback surface opposite the front surface. The reinforcing structures (a)are coupled with a non-edge portion of the front face at the backsurface, (b) consist of a solidified welding material, and (c) arebounded by only the back surface and the void when the reinforcingstructure(s) are coupled with the front face at the back surface.Meanwhile, the front face comprises a front face material, and thesolidified welding material comprises a filler material. Likewise, thereinforcing structure(s) form one or more layers at the back surface,and at least one of the layer(s) substantially forms one of a spiralpattern, a cross pattern, or a striped pattern. Further still, the clubhead comprises one of a driver-type club head, a fairway wood-type clubhead, a hybrid-type club head, an iron-type club head, a wedge-type clubhead, or a putter-type club head.

Further embodiments include a method. The method comprises: providing afront face of a club head, where the front face comprises a frontsurface and a back surface opposite the front surface; and providing oneor more reinforcing structures at the back surface of the front face,wherein (a) the one or more reinforcing structures consist of asolidified welding material, and (b) the one or more reinforcingstructures are devoid of adjoining structure other than the front face.

Turning to the drawings, FIG. 1 illustrates a rear view of front face100 for a club head when front face 100 is apart from the club head,according to an embodiment. Front face 100 is merely exemplary and isnot limited to the embodiments presented herein. Front face 100 can beemployed in many different embodiments or examples not specificallydepicted or described herein. Meanwhile, the club head can be similar oridentical to club head 250 (FIG. 2), as described below.

Front face 100 comprises front surface 101, back surface 102, and cancomprise one or more reinforcing structures 103. Back surface 102 isopposite front surface 101 and comprises back surface portion 105.Meanwhile, back surface portion 105 can correspond to a front surfaceportion (described below) of front surface 101. Accordingly, the frontsurface portion can be located opposite back surface portion 105.Further, back surface portion 105 can comprise central region 104located approximately centrally within back surface portion 105. In FIG.1, reinforcing structure(s) 103 comprises three reinforcing structures.

Reinforcing structure(s) 103 are coupled with front face 100 at backsurface 102. For example, reinforcing structure(s) 103 can be coupled tosome or all of back surface portion 105 (e.g., at approximately centralregion 104). As another example, reinforcing structure(s) 103 can becoupled to a non-edge portion of back surface 102. In further examples,reinforcing structure(s) 103 can be coupled to one or more otherportions of back surface 102, instead of or in addition to back surfaceportion 105. Meanwhile, in many embodiments, reinforcing structure(s)103 can be coupled to back surface 102 symmetrically about (a) a centerof back surface 102, (b) a center of back surface portion 105 and/or (c)central region 104 and/or about one or more reference axes intersecting(x) the center of back surface 102, (y) the center of back surfaceportion 105 and/or (z) central region 104.

Front face 100 comprises a front face material, and reinforcingstructure(s) 103 can comprise solidified welding material. Thesolidified welding material can comprise a filler material (and thefront face material). In some embodiments, when reinforcing structure(s)103 comprise multiple reinforcing structures, each of the multiplereinforcing structures can comprise the same solidified welding material(i.e., the multiple reinforcing structures comprise the same fillermaterial), and/or one or more of the reinforcing structures can comprisedifferent solidified welding material(s) from one or more otherreinforcing structures of the multiple reinforcing structures (i.e.,where some or all of the multiple reinforcement structures comprisedifferent filler materials). Accordingly, although for convenience andclarity of illustration, the solidified welding material is describedwith respect to one solidified welding material, the same details can beapplied to multiple solidified welding materials.

In many embodiments, the filler material can comprise and/or be the samematerial as the front face material. In other embodiments, the fillermaterial and the front face material can be different materials (e.g.,the filler material can be stronger or weaker than the front facematerial).

In many embodiments, the front face material and/or the filler materialcan each comprise one or more suitable metal(s), metal alloy(s), and/orthermoplastic(s) that can be used for welding. Exemplary metal(s) cancomprise iron, aluminum, and titanium (e.g., commercially pure titaniumranging in purity from approximately 98.5% to approximately 99.5%, suchas, for example, Grade 1 titanium (Commercially Pure-1), Grade 2titanium (Commercially Pure-2), Grade 3 titanium (Commercially Pure-3)),etc. Commercially pure titanium can vary from one grade to another basedon variations in the residual (e.g., interstitial) composition ofoxygen, nitrogen, hydrogen, carbon, and/or iron present therein.Exemplary metal alloy(s) can comprise any suitable iron alloy(s) (e.g.,steel), aluminum alloy(s), and/or titanium alloy(s), etc. Exemplarytitanium alloy(s) can comprise Grade 5 titanium alloy (Ti-6Al-4V), Grade9 titanium alloy (Ti-3Al-2.5V), Grade 23 titanium alloy (Ti-6Al-4V ELI(extra low interstitial)), Ti-8Al-1Mo-1V titanium alloy, Ti-5Al-2.5Sntitanium alloy, Ti-6Al-2Sn-4Zr-2Mo titanium alloy, Ti-5Al-5Sn-2Zr-2Motitanium alloy, Ti-6Al-2Nb-1Ta-1 Mo titanium alloy, Ti-3Al-13V-11Crtitanium alloy, Ti-11.5Mo-6Zr-4.5Sn titanium alloy, Ti-8Mo-8V-2Fe-3Altitanium alloy, Ti-15V-3Cr-3Al-3Sn titanium alloy, Ti-3Al-8V-6Cr-4Zr-4Motitanium alloy, Ti-2Mo-1.6V-0.5Fe-4.5Al-0.3Si-0.03C titanium alloy,Ti-15V-3Cr-3Sn-3Al titanium alloy, Ti-10V-2Fe-3Al titanium alloy,Ti-4.5Al-3V-2Mo-2Fe titanium alloy, Dat51 titanium alloy, etc. In manyexamples, these exemplary titanium alloy(s) and/or other titaniumalloy(s) can also comprise residual (e.g., interstitial) oxygen,nitrogen, hydrogen, carbon, and/or iron, etc.

Filler materials for welding are conventionally classified according tovarious specifications, such as, for example, the American WeldingSociety (AWS) specification (e.g., AWS A5.16) and/or the AerospaceMaterial Specification (AMS) (e.g., AMS 4951, AMS, 4954, AMS 4956,etc.). Meanwhile, filler materials can further be classified accordingto various grades within those specifications. Exemplary grades fortitanium/titanium alloy-based filler materials under the AWS A5.16specification can comprise ERTi-1, ERTi-2, ERTi-3, ERTi-4, ERTi-5,ERTi-5 ELI, ERTi-7, ERTi-9, ERTi-12, ERTi-23, etc. Generally speaking,these grades can correspond to the grade of the material of the basewelding material (e.g., the front face material).

In many embodiments, the filler material can be chosen according to thefront face material. Accordingly, in various embodiments, the fillermaterial can comprise and/or be the same as the front face material orcan comprise another material one grade below the front face material.For example, when the front face material comprises Grade 1 titanium(Commercially Pure-1) and/or Grade 1 titanium (Commercially Pure-1), thefiller material can comprise AWS A5.16 ERTi-2 titanium alloy, etc. Whenthe front face material comprises Grade 3 titanium (CommerciallyPure-3), the filler material can comprise AWS A5.16 ERTi-3 titaniumalloy, AWS A5.16 ERTi-9 titanium alloy, AWS A5.16 ERTi-9 ELI titaniumalloy, etc. When the front face material comprises Grade 5 (Ti-6Al-4V)titanium alloy, the filler material can comprise AWS A5.16 ERTi-5titanium alloy, AWS A5.16 ERTi-23 titanium alloy, etc. When the frontface material comprises Grade 23 (Ti-6Al-4V ELI) titanium alloy, thefiller material can comprise AWS A5.16 ERTi-23 titanium alloy, etc.

The choice of the front face material and/or the filler material canaffect and/or change and/or alter the strength, vibrational frequency,and/or durability of front face 100 and/or club head 250 (FIG. 2). As aresult, depending on the front face material and/or filler materialused, the strength, vibrational frequency, and/or durability of frontface 100 and/or club head 250 (FIG. 2) can be tuned as desired.Likewise, the front face material and/or filler material used can affectand/or change and/or alter the coefficient of restitution and/or theYoung's modulus of elasticity of front face 100 and/or club head 250(FIG. 2). For example, pairing a higher purity grade oftitanium/titanium alloy (e.g., ERTi-2) filler material (as opposed to alower purity grade of titanium/titanium alloy (e.g., ERTi-5)) with atitanium/titanium alloy face material can reduce the vibrationalfrequency of front face 100 and/or club head 250 (FIG. 2). In otherexamples, pairing a lower purity grade of titanium/titanium alloy (e.g.,ERTi-5) filler material (as opposed to a higher purity grade oftitanium/titanium alloy (e.g., ERTi-2)) with a titanium/titanium alloyface material can increase the strength of front face 100 and/or clubhead 250 (FIG. 2). Specifically, in these examples, ERTi-2 can comprisea yield strength of approximately 344.7 Mega-pascals (MPa) and ERTi-5can comprise a yield strength of approximately 896.3 MPa. In stillfurther examples, pairing one grade of titanium/titanium alloy (e.g.,ERTi-5) filler material (as opposed to another grade oftitanium/titanium alloy (e.g., ERTi-2)) with a titanium/titanium alloyface material (e.g., Grade 2 titanium) can alter the Young's modulus ofelasticity of front face 100 and/or club head 250 (FIG. 2) differently.Specifically, in these examples, ERTi-2 can comprise a Young's modulusof elasticity of approximately 103 Giga-pascals (GPa), ERTi-5 cancomprise a Young's modulus of elasticity of approximately 114 GPa, andGrade 2 titanium can comprise a Young's modulus of elasticity ofapproximately 103 GPa. Accordingly, in these examples, pairing ERTi-5filler material with Grade 2 titanium face material can result in frontface 100 and/or club head 250 (FIG. 2) comprising a higher Young'smodulus of elasticity than when pairing ERTi-2 filler material with theGrade 2 titanium face material.

Meanwhile, metallurgical treatment(s) (e.g., annealing, cold-working,age hardening, etc.) performed on front face 100 and/or reinforcingstructure(s) 103 while and/or after reinforcing structure(s) 103 arecoupled with front face 100 at back surface 102 can also affect and/orchange and/or alter the strength, vibrational frequency, durability,coefficient of restitution, and/or the Young's modulus of elasticity offront face 100 and/or club head 250 (FIG. 2). In many examples, frontface 100 and/or reinforcing structure(s) 103 can be annealed afterreinforcing structure(s) 103 are coupled with front face 100 at backsurface 102.

In many embodiments, each reinforcing structure of reinforcingstructure(s) 103 can comprise a length greater than or equal toapproximately 1.000 centimeters and less than or equal to approximately5.000 centimeters. Also, reinforcing structure of reinforcingstructure(s) 103 can comprise a width greater than or equal toapproximately 0.1905 centimeters and less than or equal to approximately0.3175 centimeters. Where the width exceeds 0.3175 centimeters, excessheat produced when coupling reinforcing structure(s) 103 to front face100 can warp front face 100 and/or change the grain structure of thefront face material.

Further still, each reinforcing structure of reinforcing structure(s)103 can comprise a thickness greater than or equal to approximately0.0381 centimeters and less than or equal to approximately 0.1905centimeters. The thickness of each reinforcing structure of reinforcingstructure(s) 103 can refer to a distance that reinforcing structure ofreinforcing structure(s) 103 projects away from back surface 102 whencoupled to back surface 102. Further, when reinforcing structure(s) 103are layered (e.g., stacked) at back surface 102 to form one or morelayers, as described below, each reinforcing structure of reinforcingstructure(s) 103, regardless of layer, can comprise a thickness greaterthan or equal to approximately 0.0381 centimeters and less than or equalto approximately 0.1905 centimeters. Meanwhile, reinforcing structure(s)103 can comprise a total thickness or a summation of the thickness(es)of the reinforcing structure(s) at each of the layer(s) formed at backsurface 102. For example, where reinforcing structure(s) 103 form twolayers at back surface 102 and the reinforcing structure(s) at eachlayer comprise thicknesses of 0.0500 centimeters, the total thickness ofreinforcing structure(s) 103 can be 0.100 centimeters. Accordingly, insome embodiments, when reinforcing structure(s) 103 are layered (e.g.,stacked) at back surface 102 to form one or more layers, each of thereinforcing structure(s) within each layer of the layer(s) can compriseapproximately the same thickness of the other reinforcing structure(s)therein. In other embodiments, the reinforcing structure(s) within eachlayer can comprise one or more different thicknesses.

Further, front face 100 can comprise an average front face thickness(i.e., an average distance between front surface 101 and back surface102) of greater than or equal to approximately 0.1778 centimeters andless than or equal to approximately 0.3810 centimeters. Thus, in variousexamples, a ratio of the total thickness of reinforcing structure(s) 103to the average front face thickness can be greater than or equal toapproximately 0.1 and less than or equal to approximately 1.1.

Reinforcing structure(s) 103 are devoid of adjoining structure (e.g.,structure coupled to reinforcing structure(s) 103) other than front face100. Accordingly, the adjoining structure does comprise front face 100,which is coupled to reinforcing structure(s) 103. Said another way,reinforcing structure(s) 103 do not operate to couple another structureto front face 100. For example, reinforcing structure(s) 103 can beformed partially from a molten part of front face 100 combined with amolten filler material that has hardened into the solidified weldingmaterial without coupling any additional structure to back surface 102of front face 100. Meanwhile, although reinforcing structure(s) 103 aredescribed as being devoid of an adjoining structure other than frontface 100, this statement does not imply that reinforcing structure(s)103 are devoid of each other. For example, two or more reinforcingstructures of reinforcing structure(s) 103 can be coupled to each otherwhile also being coupled to front face 100. More specifically, the twoor more reinforcing structures of reinforcing structure(s) 103 can becoupled (and in many examples, directly connected) to one another sideby side (e.g., forming a plane parallel to back surface 102) and/orwhere arranged in multiple layers, as described below, one on top ofanother (e.g., stacked to form a plane orthogonal and/or skewed fromback surface 102). Still, in the same or other embodiments, two or morereinforcing structures of reinforcing structure(s) 103 can be coupledwith front face 100 apart from each other (e.g., without being directlyconnected together).

Beyond the materials and/or metallurgical treatments used for the frontface material and/or the filler material, coupling reinforcingstructure(s) 103 with front face 100 at back surface 102, in general,can also affect and/or change and/or alter the strength, vibrationalfrequency, durability, coefficient of restitution, and/or the Young'smodulus of elasticity of front face 100 and/or club head 250 (FIG. 2).As a result, depending on the placement, arrangement, pattern, etc. ofreinforcing structure(s) 103, the strength, vibrational frequency,durability, coefficient of restitution, and/or the Young's modulus ofelasticity of front face 100 and/or club head 250 (FIG. 2) can be tunedas desired. Meanwhile, because coupling reinforcing structure(s) 103 canaffect and/or change and/or alter the strength, vibrational frequency,durability, coefficient of restitution, and/or the Young's modulus ofelasticity of front face 100 and/or club head 250 (FIG. 2) without using(e.g., coupling) and/or needing additional adjoining structure to do so,cost savings in manufacturing front face 100 and/or club head 250 (FIG.2) can be realized.

Turning to the next drawing, FIG. 2 illustrates an x-ray view of frontface 100 when front face 100 is part of club head 250, according to theembodiment of FIG. 1. Accordingly, in many embodiments, club head 250can comprise front face 100 (FIG. 1), reinforcing structure(s) 103 (FIG.1), and/or void 253, as illustrated by the cut-out at FIG. 2.

Void 253 can be adjacent to back surface 102 (FIG. 1) and/orreinforcement structure(s) 103 (FIG. 1). Meanwhile, reinforcingstructure(s) 103 (FIG. 1) can be bounded and/or defined by back surface102 and void 253 when reinforcing structure(s) 103 are coupled withfront face 100 (FIG. 1) at back surface 102 (FIG. 1). Void 253 can referto a volume that is devoid of reinforcing structure(s) 103. Void 253 canbe an empty space (e.g., a hollow space, a cavity, an open space, etc.),but in many embodiments, can still be filled with material, such as, forexample, damping material (e.g., foam).

The relationship of void 253 to reinforcing structure(s) 103 (FIG. 1)illustrates that reinforcing structure(s) 103 are devoid of adjoiningstructure. However, the relationship of void 253 to reinforcingstructure(s) 103 also illustrates that while reinforcing structure(s)103 (FIG. 1) are not coupled to adjoining structure other than frontface 100 (FIG. 1), reinforcing structure(s) 103 (FIG. 1) can still beadjacent to other structure, such as, for example, any material at void253, but does not couple the other structure to front face 100.

Club head 250 can comprise any suitable golf club head (e.g., awood-type golf club head, such as, for example, a driver-type golf clubhead or a fairway wood-type golf club head), a hybrid-type golf clubhead, an iron-type golf club, a wedge-type golf club, and/or aputter-type golf club, etc.). For example, front face 100 (FIG. 1) cancomprise a strike face of club head 250 Accordingly, front surface 101(FIG. 1) can comprise a striking surface of the strike face for hittinga golf ball. Front face 100 (FIG. 1) can be (a) an integral component ofclub head 250 and/or (b) an interchangeable/removable component of clubhead 250.

Further, with front face 100 (FIG. 1) comprising the strike face of clubhead 250, the front surface portion (introduced above) of front surface101 can refer to a portion of the striking surface of the strike facethat provides a target strike zone with the golf ball (e.g.,approximately maximizing force transfer while approximately minimallydeviating from a desired flight path, such as, for example, astraight-line flight path) when hitting the golf ball. Accordingly, thefront surface portion can be defined relative to any predeterminedand/or established tolerances for maximum force transfer (e.g., greaterthan or equal to approximately 90 percent, 92 percent, 95 percent, 98percent, etc.) and/or minimum flight path deviation (e.g., less than orequal to approximately 0.5 degrees, 1.0 degrees, 2.0 degrees, 5.0degrees, etc.). Thus, the front surface portion can increase in size asthe predetermined and/or established tolerances become less strict andcan decrease in size as the predetermined and/or established tolerancesbecome more strict. Meanwhile, as indicated above, back surface portion105 (FIG. 1) can correspond to the front surface portion of front face100 and can be coupled with reinforcing structure(s) 103 (FIG. 1) toreinforce the front face portion of front face 100 (FIG. 1).

Turning back to FIG. 1, in various embodiments, back surface portion 105(FIG. 1) can comprise a back surface portion surface area of greaterthan or equal to approximately 3.225 square centimeters and less than orequal to approximately 9.678 square centimeters. Accordingly, the frontsurface portion of front surface 101 can also comprise a front surfaceportion surface area of greater than or equal to approximately 3.225square centimeters and less than or equal to approximately 9.678 squarecentimeters. Further, reinforcing structure(s) 103 can comprise areinforcing structure total surface area of greater than or equal toapproximately 1.612 square centimeters and less than or equal toapproximately 22.58 square centimeters.

Further, back surface 102 can comprise a back surface total surfacearea, which can comprise the back surface portion surface area. Invarious examples, a ratio of the reinforcing structure total surfacearea to the back surface total surface area can be greater than or equalto approximately 0.004 and less than or equal to approximately 0.560.

In many embodiments, the total thickness of reinforcing structure(s) 103can be proportional (e.g., directly proportional) to the back surfacetotal surface area. For example, where front face 100 is part of clubface 250 (FIG. 2) and club face 250 comprises a driver-type golf clubhead, the back surface total surface area can be greater than where clubface 250 comprises a fairway wood-type golf club head, such as, forexample, because an average height of front face 100 (e.g., an averagedistance between a crown and a sole of club head 250 (FIG. 2)) can begreater where club face 250 comprises the driver-type golf club headthan where club face 250 comprises the fairway wood-type golf club head.

As mentioned above, reinforcing structure(s) 103 can be layered (e.g.,stacked) at back face surface 102 to form one or more layers. Stackingmultiple layers of reinforcing structure(s) 103 can additionally affectand/or change and/or alter the strength, vibrational frequency,durability, coefficient of restitution, and/or the Young's modulus ofelasticity of front face 100 and/or club head 250 (FIG. 2), wheredesired.

Likewise, each layer of reinforcing structure(s) 103 can substantiallyform a pattern. For example, the pattern can comprise a striped pattern(e.g., striped pattern 305 (FIG. 3)), a spiral pattern (e.g., spiralpattern 406 (FIG. 4)), a cross pattern (e.g., cross pattern 507 (FIG.5)), and/or any other suitable pattern, such as, for example, asillustrated at FIGS. 1 and 2. The stripe pattern can be vertical and/orhorizontal. The spiral pattern can be welded from central region 104outward, or vice versa. Meanwhile, where reinforcing structure(s) 103are layered in multiple layers, when each of the multiple layerscomprises a striped pattern, each progressive layer can switch fromhorizontal stripes to vertical stripes, and vice versa. Likewise, wherereinforcing structure(s) 103 are layered in multiple layers, the weldarea of each progressive layer can be smaller than that of the prior orunderlying layer, where the weld area is greatest closest to backsurface 102.

Depending on the pattern formed, each layer of reinforcing structure(s)103 can approximately form a shape (e.g., a cross, a circle, aquadrilateral, etc.). In many embodiments, the pattern and correspondingshape of reinforcing structure(s) can affect the concentration of stressat front face 100 such that it can be desirable to use a pattern (andshape) that minimizes the concentration of stress at front face 100. Insome embodiments, reinforcing structure(s) 103 can be polished to reducethe concentration of stress at front face 100 as well.

Further, as mentioned previously, the pattern and corresponding shape ofreinforcing structure(s) formed can affect and/or change and/or alterthe strength, vibrational frequency, durability, coefficient ofrestitution, and/or the Young's modulus of elasticity of front face 100and/or club head 250 (FIG. 2). Accordingly, the pattern and/orcorresponding shape can be chosen to affect and/or change and/or alterthe strength, vibrational frequency, durability, coefficient ofrestitution, and/or the Young's modulus of elasticity of front face 100and/or club head 250 (FIG. 2) as desired.

Skipping ahead in the drawings, FIG. 3 illustrates a rear view of frontface 300 of a club head when front face 300 is apart from the club head.Front face 300 is similar to front face 100 (FIG. 1), and the club headis similar to club head 250 (FIG. 2). Accordingly, front face 300comprises front surface 301 and back surface 302, which are similar oridentical to front surface 101 (FIG. 1) and back surface 102 (FIG. 1),respectively. Meanwhile, reinforcing structure(s) 303 are coupled withfront face 300 at back surface 302. Reinforcing structure(s) 303 aresimilar to reinforcing structure(s) 103 (FIG. 1) and form stripedpattern 305.

Meanwhile, FIG. 4 illustrates a rear view of front face 400 of a clubhead when front face 400 is apart from the club head. Front face 400 isalso similar to front face 100 (FIG. 1), and the club head is alsosimilar to club head 250 (FIG. 2). Accordingly, front face 400 comprisesfront surface 401 and back surface 402, which are similar or identicalto front surface 101 (FIG. 1) and back surface 102 (FIG. 1),respectively. Meanwhile, reinforcing structure(s) 403 are coupled withfront face 400 at back surface 402. Reinforcing structure(s) 403 aresimilar to reinforcing structure(s) 103 (FIG. 1) and form spiral pattern406. In FIG. 4, reinforcing structure(s) 403 comprise a singlereinforcing structure.

Furthermore, FIG. 5 illustrates a rear view of front face 500 of a clubhead when front face 500 is apart from the club head. Front face 500 isalso similar to front face 100 (FIG. 1), and the club head is alsosimilar to club head 250 (FIG. 2). Accordingly, front face 500 comprisesfront surface 501 and back surface 502, which are similar or identicalto front surface 101 (FIG. 1) and back surface 102 (FIG. 1),respectively. Meanwhile, reinforcing structure(s) 503 are coupled withfront face 500 at back surface 502. Reinforcing structure(s) 503 aresimilar to reinforcing structure(s) 103 (FIG. 1) and form cross pattern507. In FIG. 5, reinforcing structure(s) 503 comprise eight reinforcingstructures.

Turning now to the next drawing, FIG. 6 illustrates a flow chart for anembodiment of method 600 of providing a club head. Method 600 is merelyexemplary and is not limited to the embodiments presented herein. Method600 can be employed in many different embodiments or examples notspecifically depicted or described herein. In some embodiments, theprocedures, the processes, and/or the activities of method 600 can beperformed in the order presented. In other embodiments, the procedures,the processes, and/or the activities of method 600 can be performed inany other suitable order. In still other embodiments, one or more of theprocedures, the processes, and/or the activities in method 600 can becombined or skipped. The club head can be similar or identical to clubhead 250 (FIG. 2).

Method 600 can comprise procedure 601 of providing the front face tocomprise a front surface and a back surface opposite the front surface.The front surface can be similar or identical to front surface 101 (FIG.1), front surface 301 (FIG. 3), front surface 401 (FIG. 4), and/or frontsurface 501 (FIG. 5). Meanwhile the back surface can be similar oridentical to back surface 102 (FIG. 1), back surface 302 (FIG. 3), backsurface 402 (FIG. 4), and/or back surface 502 (FIG. 5). FIG. 7illustrates an exemplary procedure 601.

Procedure 601 can comprise process 701 of providing a front facematerial. The front face material can be similar or identical to thefront face material described above with respect to front face 100 (FIG.1).

Procedure 601 can comprise process 702 of cutting a sheet of the frontface material (e.g., with one of a laser or a water jet) to form thefront face; and procedure 601 can comprise process 703 of hot pressingthe front face to form a bulge and roll of the front face. In someembodiments, process 702 and/or process 703 can be omitted, such as, forexample, where the front face material is already cut and/or shaped.

Procedure 601 can comprise process 704 of cleaning at least the backsurface of the front face. Process 704 can be performed beforeperforming part or all of procedure 602 (FIG. 6). Performing process 704can comprise acid cleaning at least the back surface of the front faceand/or wiping at least the back surface of the front face with one ormore solvents (e.g., one or more non-chlorinated solvent, such as, forexample, acetone, toluene, methyl ethyl ketone (MEK), etc.) using one ormore lint-free cloths and/or cellulose sponges in a manner that leavessubstantially no residue behind from the lint-free cloth(s) and/orcellulose sponge(s). Performing process 704 can remove substantially anycontaminants (e.g., mill scale, dirt, dust, grease, oil, moisture, etc.)from the back surface and/or the front face that can degrade themechanical properties and/or corrosion resistance of the front faceand/or that can degrade the subsequently formed bond between the frontface and the one or more reinforcing structures. Solvents can beparticularly effective for removing grease and/or oil. Where performingprocess 704 comprises wiping at least the back surface of the front facewith one or more solvents, performing process 704 can further comprisewire brushing (e.g., with a stainless steel brush, steel brush, steelwool, etc.) at least the back surface of the front face after wiping atleast the back surface of the front face with the one or more solvents.Where the front face material comprises titanium, stainless steelbrushes can be used to avoid reduction of corrosion resistance in thefront face and/or embedding iron particles in the front face.

Procedure 601 can comprise process 705 of smoothing at least the backsurface of the front face. Performing process 705 can comprise filingthe back surface of the front face, such as, for example, to remove burnmarks, burrs, and/or sharp edges from the back surface of the frontface. Although sand paper and steel wool can be also be used to performprocess 705, sand paper and steel wool can leave behind undesirablecontaminants, which can be avoided by using a sharp file instead.Process 705 can be performed before performing part or all of procedure602 (FIG. 6). In some embodiments, process 704 and/or process 705 can beomitted.

Returning to FIG. 6, method 600 can comprise procedure 602 of providingone or more reinforcing structures at the back surface of the frontface. The reinforcing structure(s) can be similar or identical toreinforcing structure(s) 103 (FIG. 1), reinforcing structure(s) 303(FIG. 3), reinforcing structure(s) 403 (FIG. 4), and/or reinforcingstructure(s) 503 (FIG. 5). FIG. 8 illustrates an exemplary procedure602.

Procedure 602 can comprise process 801 of coupling the reinforcingstructure(s) with the front face at the back surface. In manyembodiments, process 801 can be performed at ambient temperature. FIG. 9illustrates an exemplary process 801.

Process 801 can comprise activity 901 of welding a filler material tothe back surface of the front face. The filler material can be similaror identical to the filler material described above with respect tofront face 100 (FIG. 1). Performing activity 901 can comprise arcwelding (e.g., metal inert gas (MIG) welding, tungsten inert gas (TIG)welding, etc.) the filler material to the back surface of the frontface. Activity 901 can be performed with a conventional thoriatedtungsten electrode (e.g., an AWS EWTh-1 electrode, an AWS EWTh-2electrode, etc.). Electrode size can be governed by the smallestdiameter of the electrode that is able to carry welding electriccurrent. Grinding the electrode to a point can improve arc initiationand/or control the spread of the arc. The electrode can extend 1.5 timesthe size of the diameter beyond the end of the nozzle of the welder.

When the front face material comprises an unalloyed titanium, activity901 can be performed while the front face material and/or the fillermaterial are in an annealed condition.

Process 801 can continue with activity 902 of permitting the fillermaterial to solidify into a solidified welding material of thereinforcement structure(s) such that (i) the solidified welding materialcomprises the filler material (and the front face material) and (ii) thereinforcement structure(s) are devoid of adjoining structure other thanthe front face. The solidified welding material can be similar oridentical to the solidified welding material described above withrespect to front face 100 (FIG. 1). When the solidified welding materialcomprises a low-grade titanium alloy, hydride precipitation canembrittle the solidified welding material. Performing process 704,process 705, and/or activity 904 can help reduce and/or prevent hydrideprecipitation.

In some embodiments, process 801 can comprise activity 903 of weldingthe filler material to other filler material at the back surface of thefront face. Performing activity 903 can be similar to performingactivity 901. In these embodiments, activity 902 and activity 903 can berepeated. In various embodiments, activity 901, activity 902, and/oractivity 903 can be performed as part of process 803 (FIG. 8) and/orprocess 804 (FIG. 8). In other embodiments, activity 903 can be omitted.

Process 801 can also comprise activity 904 of shielding the reinforcingstructure(s) from air contamination using one or more inert gases, suchas, for example, until the temperature of the reinforcing structure(s)falls below a temperature (e.g., approximately 427° C.). Exemplary inertgas(es) comprise argon, helium, etc. Using argon to shield thereinforcing structure(s) can permit superior arc stability for welding,and using argon-helium gas mixtures can permit welding at highervoltages, hotter arcs, and/or at greater depths of penetration.Generally speaking, using argon can also be cheaper than using helium.Activity 804 can be performed while performing activity 901, activity902, and/or activity 903.

Turning back to FIG. 8, procedure 602 can comprise process 802 ofproviding the filler material. In some embodiments, process 802 can beperformed as part of process 801.

Procedure 602 can further comprise process 803 of arranging thereinforcement structure(s) in one or more layers. The layer(s) can besimilar or identical to the layer(s) described above with respect tofront face 100 (FIG. 1).

Procedure 602 can also comprise process 804 of arranging each of thelayer(s) to form a pattern. The pattern(s) can be similar or identicalto the pattern(s) described above with respect to front face 100 (FIG.1).

Procedure 602 can additionally comprise process 805 of altering thestrength, the vibrational frequency, the durability, the coefficient ofrestitution, and/or the Young's modulus of the front face and/or theclub head. Processes 803, 804, and/or 805 can occur simultaneously witheach other.

Procedure 602 can comprise process 806 of polishing the reinforcementstructure(s) and/or the front face to reduce stress concentrations atthe front face. Performing process 806 can comprise shot peening,milling (e.g., computer numerical controlled (CNC) milling), and/or handpolishing the reinforcement structure(s) and/or the front face.

Returning again to FIG. 6, method 600 can comprise procedure 603 ofproviding the club head. In some embodiments, procedure 601 and/orprocedure 602 can be performed as part of procedure 603. Performingprocedure 603 can comprise welding the front face to another portion ofthe club head via robotic plasma welding.

Although the invention has been described with reference to specificembodiments, it will be understood by those skilled in the art thatvarious changes may be made without departing from the spirit or scopeof the invention. Accordingly, the disclosure of embodiments of theinvention is intended to be illustrative of the scope of the inventionand is not intended to be limiting. It is intended that the scope of theinvention shall be limited only to the extent required by the appendedclaims. For example, to one of ordinary skill in the art, it will bereadily apparent that procedures 601-603 of FIG. 6, processes 701-705 ofFIG. 7, processes 801-806 of FIG. 8, and/or activities 901-904 of FIG. 9may be comprised of many different procedures, processes, and/oractivities and be performed by many different modules, in many differentorders, that any element of FIGS. 1-9 may be modified, and that theforegoing discussion of certain of these embodiments does notnecessarily represent a complete description of all possibleembodiments.

All elements claimed in any particular claim are essential to theembodiment claimed in that particular claim. Consequently, replacementof one or more claimed elements constitutes reconstruction and notrepair. Additionally, benefits, other advantages, and solutions toproblems have been described with regard to specific embodiments. Thebenefits, advantages, solutions to problems, and any element or elementsthat may cause any benefit, advantage, or solution to occur or becomemore pronounced, however, are not to be construed as critical, required,or essential features or elements of any or all of the claims, unlesssuch benefits, advantages, solutions, or elements are expressly statedin such claim.

As the rules to golf may change from time to time (e.g., new regulationsmay be adopted or old rules may be eliminated or modified by golfstandard organizations and/or governing bodies such as the United StatesGolf Association (USGA), the Royal and Ancient Golf Club of St. Andrews(R&A), etc.), golf equipment related to the apparatus, methods, andarticles of manufacture described herein may be conforming ornon-conforming to the rules of golf at any particular time. Accordingly,golf equipment related to the apparatus, methods, and articles ofmanufacture described herein may be advertised, offered for sale, and/orsold as conforming or non-conforming golf equipment. The apparatus,methods, and articles of manufacture described herein are not limited inthis regard.

While the above examples may be described in connection with a wood-typegolf club head (e.g., a driver-type golf club head or a fairwaywood-type golf club head) or a hybrid-type golf club head, theapparatus, methods, and articles of manufacture described herein may beapplicable to other types of golf clubs such as an iron-type golf club,a wedge-type golf club, or a putter-type golf club. Alternatively, theapparatus, methods, and articles of manufacture described herein may beapplicable other type of sports equipment such as a hockey stick, atennis racket, a fishing pole, a ski pole, etc.

Moreover, embodiments and limitations disclosed herein are not dedicatedto the public under the doctrine of dedication if the embodiments and/orlimitations: (1) are not expressly claimed in the claims; and (2) are orare potentially equivalents of express elements and/or limitations inthe claims under the doctrine of equivalents.

What is claimed is:
 1. A method comprising: providing a front face of a club head, the front face comprising a front surface and a back surface opposite the front surface; and providing one or more reinforcing structures at the back surface of the front face; wherein: the one or more reinforcing structures consist of a solidified welding material; and the one or more reinforcing structures are devoid of adjoining structure other than the front face; providing the one or more reinforcing structures at the back surface of the front face comprises: coupling the one or more reinforcing structures with the front face at the back surface; coupling the one or more reinforcing structures with the front face at the back surface comprises: welding a filler material to the back surface of the front face, the solidified welding material comprising the filler material; and welding the filler material to the back surface of the front face comprises: arc welding the filler material to the back surface of the front face.
 2. The method of claim 1 wherein: providing the one or more reinforcing structures at the back surface of the front face comprises: coupling the one or more reinforcing structures with the front face at a non-edge portion separate from a perimeter edge of the back surface.
 3. The method of claim 1 wherein: providing the front face comprises providing a front face material.
 4. The method of claim 1 wherein: providing the one or more reinforcing structures comprises: arranging the one or more reinforcing structures in one or more layers, and arranging each of the one or more layers to form one of a spiral pattern or a multi-striped pattern.
 5. The method of claim 1 wherein: providing the one or more reinforcing structures comprises altering at least one of: a strength of the front face; a vibrational frequency of the front face; or a Young's modulus of elasticity of the front face.
 6. The method of claim 1 further comprising: providing a club head, the club head comprising one of a driver-type club head, a fairway wood-type club head, a hybrid-type club head, an iron-type club head, a wedge-type club head, or a putter-type club head; wherein: providing the club head comprises providing the front face and providing the one or more reinforcing structures.
 7. A method comprising: providing a front face of a club head, the front face comprising a front surface and a back surface opposite the front surface; and providing one or more reinforcing structures at the back surface of the front face; wherein: the one or more reinforcing structures consist of a solidified welding material; and the one or more reinforcing structures are devoid of adjoining structure other than the front face; providing the one or more reinforcing structures at the back surface of the front face comprises: coupling the one or more reinforcing structures with the front face at the back surface; coupling the one or more reinforcing structures with the front face at the back surface comprises: welding a filler material to the back surface of the front face, the solidified welding material comprising the filler material; welding the filler material to the back surface of the front face comprises: arc welding the filler material to the back surface of the front face; and arc welding the filler material to the back surface of the front face comprises one of: metal inert gas welding the filler material to the back surface of the front face; or tungsten inert gas welding the filler material to the back surface of the front face.
 8. A method comprising: providing a front face of a club head, the front face comprising a front surface and a back surface opposite the front surface; and providing one or more reinforcing structures at the back surface of the front face; wherein: the one or more reinforcing structures consist of a solidified welding material; and the one or more reinforcing structures are devoid of adjoining structure other than the front face; providing the one or more reinforcing structures at the back surface of the front face comprises: coupling the one or more reinforcing structures with the front face at the back surface, wherein the front face comprises a front face material; and coupling the one or more reinforcing structures with the front face at the back surface comprises: welding a filler material to the back surface of the front face while the front face material and the filler material are in an annealed condition, the solidified welding material comprising the filler material. 